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Course 714
Fall Protection Program
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OSHAcademy Course 714 Study Guide
Fall Protection Program
Copyright © 2016 Geigle Safety Group, Inc.
No portion of this text may be reprinted for other than personal use. Any commercial use of this document is strictly forbidden.
Contact OSHAcademy to arrange for use as a training document.
This study guide is designed to be reviewed off-line as a tool for preparation to successfully complete OSHAcademy Course 714.
Read each module, answer the quiz questions, and submit the quiz questions online through the course webpage. You can print the post-quiz response screen which will contain the correct answers to the questions.
The final exam will consist of questions developed from the course content and module quizzes.
We hope you enjoy the course and if you have any questions, feel free to email or call:
OSHAcademy
15220 NW Greenbrier Parkway, Suite 230 Beaverton, Oregon 97006 www.oshatrain.org [email protected] +1 (888) 668-9079
Disclaimer
This document does not constitute legal advice. Consult with your own company counsel for advice on compliance with all applicable state and
federal regulations. Neither Geigle Safety Group, Inc., nor any of its employees, subcontractors, consultants, committees, or other assignees
make any warranty or representation, either express or implied, with respect to the accuracy, completeness, or usefulness of the information
contained herein, or assume any liability or responsibility for any use, or the results of such use, of any information or process disclosed in this
publication. GEIGLE SAFETY GROUP, INC., DISCLAIMS ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING, WITHOUT LIMITATION, ANY
WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Taking actions suggested in this document does not guarantee
that an employer, employee, operator or contractor will be in compliance with applicable regulations. Ultimately every company is responsible
for determining the applicability of the information in this document to its own operations. Each employer’s safety management system will be
different. Mapping safety and environmental management policies, procedures, or operations using this document does not guarantee
compliance regulatory requirements.
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Course 714
Contents
Course Introduction ........................................................................................................................ 1
Why We Need Fall Protection ..................................................................................................... 1
What the Fall Protection Standard Covers ................................................................................. 1
Module 1: Important Questions ..................................................................................................... 2
Why We Need Protection from Falling ....................................................................................... 2
When Fall Protection is Needed ................................................................................................. 2
How Workers Fall ........................................................................................................................ 4
The Importance of the Fall Protection Program ......................................................................... 5
Your Role in the Fall Protection Program ................................................................................... 5
Real-World Falls .......................................................................................................................... 7
Module 1 Quiz ............................................................................................................................. 8
Module 2: Fall Protection Program Elements ............................................................................... 10
The Fall Protection Program – A System within a System ........................................................ 10
Fall Protection Program Elements ............................................................................................ 10
Prepare a Safety and Health Policy ........................................................................................... 13
Designate Competent Persons and Qualified Persons ............................................................. 13
Who Can Be Competent and Qualified Persons? ................................................................. 13
Determining Who Can Be a Competent or Qualified Person ............................................... 14
Real-World Falls ........................................................................................................................ 15
Module 2 Quiz ........................................................................................................................... 16
Module 3: Identifying and Evaluating Fall Hazards ...................................................................... 18
Fall Hazard Defined ................................................................................................................... 18
How to Evaluate Fall Hazards.................................................................................................... 18
Course 714
Involve Others ........................................................................................................................... 18
Determine How Workers Will Access Elevated Surfaces to Perform Their Tasks .................... 18
Identify Tasks That Could Expose Workers to Falls .................................................................. 19
Identify Hazardous Work Areas ................................................................................................ 19
Determine How Frequently Workers Will Do Tasks that Expose Them to Falls ....................... 20
Determine If and How Workers Need to Move ........................................................................ 20
Determine the Degree of Exposure .......................................................................................... 20
Determine Hazardous Walking/Walking Surfaces .................................................................... 20
Determine Fall Distances .......................................................................................................... 20
Identify Fall Hazards That You Can Eliminate ........................................................................... 21
Consider Administrative Controls ............................................................................................. 21
Determine Whether Anchorages Are Necessary ...................................................................... 21
Consider Other Factors That Could Increase the Risk of Falls .................................................. 21
Module 3 Quiz ........................................................................................................................... 23
Module 4: Supported and Suspended Access .............................................................................. 25
What is Supported Access? ....................................................................................................... 25
Portable Ladders ....................................................................................................................... 25
Common types of portable ladders .......................................................................................... 25
How Falls from Ladders Occur .................................................................................................. 27
Required Ladder Safety Training ............................................................................................... 27
Safe Ladder Practices ................................................................................................................ 27
Supported Scaffolds .................................................................................................................. 28
How Falls from Scaffolds Occur ................................................................................................ 29
Training for Those Who Work from Scaffolds .......................................................................... 29
Course 714
Safe Practices While Working on Scaffolds .............................................................................. 29
Aerial Lifts ................................................................................................................................. 30
Types of Aerial Lifts ............................................................................................................... 30
How Aerial Lift Falls Occur .................................................................................................... 31
Appropriate Fall Protection .................................................................................................. 31
Safe Practices While Working on Aerial Lifts ........................................................................ 31
What is Suspended Access? ...................................................................................................... 32
Adjustable-Suspension Scaffolds .............................................................................................. 32
How Suspended Scaffold Falls Occur .................................................................................... 33
Using Adjustable-Suspension Scaffolds ................................................................................ 33
When Fall-Protection Systems Are Required............................................................................ 33
What You Should Know About Descent-Control Devices ......................................................... 34
How Falls Occur ......................................................................................................................... 34
Crane- and Derrick-Suspended Personnel Platforms ............................................................... 34
How Injuries Occur .................................................................................................................... 34
Safe Practices ............................................................................................................................ 35
Module 4 Quiz ........................................................................................................................... 36
Module 5: Fall Protection Systems ............................................................................................... 38
What is a Fall Protection System? ............................................................................................ 38
Types of Fall Protection Systems .............................................................................................. 38
Other Fall-Protection Methods ................................................................................................. 38
Identify and Evaluate Fall Hazards ............................................................................................ 39
Personal Fall-Arrest Systems (PFAS) ......................................................................................... 39
The Anchorage .......................................................................................................................... 40
Course 714
The Full-Body Harness .............................................................................................................. 41
Body Belts ................................................................................................................................. 42
Purchasing an FBH for a Personal Fall-Arrest System ............................................................... 42
Connection Systems - Lanyards ................................................................................................ 42
Beware of Swing Falls! .............................................................................................................. 44
Safe Practices for Personal Fall-Arrest Systems ........................................................................ 46
Real-World Falls ........................................................................................................................ 47
Module 5 Quiz ........................................................................................................................... 48
Module 6: Fall Protection Systems (Continued) ........................................................................... 50
Personal Fall-Restraint Systems ................................................................................................ 50
Positioning-Device Systems ...................................................................................................... 50
Guardrail Systems ..................................................................................................................... 51
Safety-Net Systems ................................................................................................................... 51
Warning-Line Systems for Roofing Work .................................................................................. 52
Slide-Guard Systems ................................................................................................................. 53
Safety Monitoring for Roofing Work ........................................................................................ 55
Catch Platforms ......................................................................................................................... 56
Covers for Holes ........................................................................................................................ 56
Fences and Barricades .............................................................................................................. 57
Protecting Workers from Falling Objects.................................................................................. 57
Module 6 Quiz ........................................................................................................................... 58
Module 7: Fall Protection Training ............................................................................................... 60
Why Workers Should Be Trained on Fall Protection ................................................................ 60
Employers: Your Responsibility................................................................................................. 60
Course 714
Required Training for Employees Exposed to Fall Hazards ...................................................... 60
The Training Format .................................................................................................................. 61
When to Train ........................................................................................................................... 62
What to Put in Writing .............................................................................................................. 62
Model Training Strategy ........................................................................................................... 63
Real-World Falls ........................................................................................................................ 65
Module 7 Quiz ........................................................................................................................... 66
Module 8: Inspection and Maintenance ....................................................................................... 68
Caring for Equipment ................................................................................................................ 68
Inspection and Maintenance .................................................................................................... 68
Harness Inspection .................................................................................................................... 68
Lanyards .................................................................................................................................... 69
Hardware .............................................................................................................................. 69
Shock-Absorbing Packs ............................................................................................................. 70
Visual Indication of Damage to Webbing and Rope Lanyards .................................................. 70
Heat ....................................................................................................................................... 70
Chemical ................................................................................................................................ 70
Ultraviolet Rays ..................................................................................................................... 70
Molten Metal or Flame ......................................................................................................... 70
Paint and Solvents ................................................................................................................. 70
Self-Retracting Lifelines ............................................................................................................ 70
Guardrail Systems ..................................................................................................................... 70
Safety-Net Systems ................................................................................................................... 71
Ladders ...................................................................................................................................... 71
Course 714
Scaffolds .................................................................................................................................... 71
Suspension scaffolds ................................................................................................................. 71
Crane- and Derrick-Suspended Personnel Platforms ............................................................... 72
Summary: Inspecting, Cleaning, and Storing Fall-Protection Equipment................................. 72
Module 8 Quiz ........................................................................................................................... 73
Module 9: Rescue at Height .......................................................................................................... 75
Prompt Rescue Required .......................................................................................................... 75
Developing an Emergency-Response Plan ................................................................................ 75
Summary: Responding to falls .................................................................................................. 77
Module 9 Quiz ........................................................................................................................... 80
Course 714
Copyright © 2015 Geigle Safety Group, Inc. Page 1 of 81
Course Introduction
Why We Need Fall Protection
Falls are among the most common causes
of serious work-related injuries and
deaths in the workplace. Employers must
take measures in their workplaces to
prevent employees from falling off
overhead platforms, elevated work
stations or into holes in the floor and
walls.
The U.S. Bureau of Labor Statistics data
shows that falls to a lower level have been
the most frequent type of fatal fall in the
workplace. Most of those are caused by
falls from roofs, ladders, scaffolds, non-
moving vehicles, and building girders or
other structural steel.
What the Fall Protection Standard Covers
For general industry, the trigger height for
providing fall protection is 4 feet.
However, there are exceptions for work in
construction, scaffolding, fixed ladders,
dangerous equipment, and utility work.
From the beginning, OSHA has
consistently reinforced the “4-foot rule.”
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Module 1: Important Questions
Why We Need Protection from Falling
We need protection because even those of us with
experience working at heights can lose our balance or grip;
we can slip, trip, or misstep at any time. We may think that
our reflexes will protect us, but we're falling before we know
it, and we don't have to fall far to be seriously injured. We've
been falling since Day One. Until we get better at landing,
we'll need protection from falling.
When Fall Protection is Needed
OSHA’s general industry standards require employers to identify the potential for falls in the
workplace and establish appropriate fall protection when they identify hazards. Four feet above
the ground or a lower level is widely understood among general industry employers as the
“trigger height” that requires you to take action to protect your employees from falls.
Did you know that some trigger heights in general industry differ from four feet? Working
above or adjacent to dangerous equipment requires action to protect employees from falls
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onto that equipment, regardless of height, and many types of scaffolds have trigger heights
above four feet.
Understanding OSHA’s fall protection trigger heights and the types of fall protection allowed in
general industry will help you protect employees. The tables in this section identify trigger
heights for a variety of general industry situations employees may encounter.
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Fall protection trigger heights are rule specific. Some trigger heights are activated when the
height is met while others are activated when the height is exceeded. When this occurs, you
must take action to protect your employees from the associated fall hazards.
Selecting, installing, maintaining, and using fall protection can be challenging. Browse through
any safety supply website today and you will see a wide variety of fall protection systems;
however, not all systems provide equivalent levels of worker protection. Furthermore, one fall
protection system may not be appropriate for every workplace situation. The rules referenced
in the tables in this section will help you select appropriate fall protection systems when your
employees work at heights that require you to take action to protect them.
How Workers Fall
Below is a list in order of priority showing the types of falls that cause the most injuries. As you
can see, most fall injuries are caused by falls from ladders.
1. Falls from ladders
2. Falls to lower levels (unspecified)
3. Falls from roofs
4. Falls from scaffolds or staging
5. Falls from non-moving vehicles
6. Falls from floors, docks, or ground level
7. Falls down stairs
8. Falls from girders or structural steel
9. Falls from piled of stacked material
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The Importance of the Fall Protection Program
An effective Fall Protection Program describes policies,
plans, processes, procedures and practices that helps
eliminate or reduce fall hazards, prevents falls, and
ensures workers who may fall aren't injured.
You accomplish fall protection by doing the following:
Make fall protection part of your workplace safety and health program.
Identify and evaluate fall hazards.
Eliminate fall hazards, if possible.
Train workers to recognize fall hazards.
Use appropriate equipment to prevent falls and to protect workers if they do fall.
Inspect and maintain fall-protection equipment before and after using it.
Become familiar with OSHA and company fall-protection rules.
Your Role in the Fall Protection Program
Everyone in the workplace has a role to play in preventing falls.
Employers: Identify fall hazards at the site. Eliminate the hazards, prevent falls from
occurring, or ensure that if falls occur, employees aren't injured. Make sure that
employees follow safe practices, use fall protection equipment properly, and are trained
to recognize fall hazards.
Employees: Follow safe work practices, use equipment properly, and participate in
training. Learn to recognize unsafe practices, know the tasks that increase the risk of
falling, and understand how to control exposure to fall hazards.
Architects and engineers: Educate employers about hazards that could expose workers
to falls during each phase of the project. When designing buildings and structures,
consider fall protection and other safety needs of those who will do the construction
work.
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Building owners and managers: Ensure that those who do exterior construction or
maintenance work know how to protect themselves from falls, are aware of installed
anchorages, and know how to use their fall-protection equipment.
Equipment manufacturers: Ensure that fall-protection equipment meets federal OSHA
and ANSI safety requirements and protects workers when they use it properly. Warn
workers through instruction manuals and on equipment labels about the danger of
using equipment improperly.
Lawyers: Review your client's construction bids to ensure that they comply with OSHA
requirements. The documents should clearly state the client's responsibilities for
protecting workers from falls and for identifying and controlling hazards that cause falls.
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Real-World Falls
Cost estimator falls through skylight opening
On a Friday in June, an estimator arrived at a remodel
job to look at a cedar-shake roof and estimate the cost
of an addition that a construction crew was building.
He spoke to the supervisor at the site and climbed to
the roof through an open skylight, using a metal
extension ladder.
However, he was unaware that the contractor had
used a sheet of thin insulating material to cover three
2-by-6-foot skylight openings in the roof (it had rained
the day before). He stepped onto the insulating material, fell through one of the skylights,
and landed on his back, 15 feet below.
The supervisor and two subcontractors heard the estimator fall and rushed to the accident.
One of the subcontractors used his cell phone to call emergency medical services. EMTs
arrived about five minutes later, stabilized the victim and took him to a hospital where he
underwent emergency surgery for spinal injuries
Findings: The employer failed to properly cover the skylight openings on the roof or warn
workers about the hazard.
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Module 1 Quiz
Use this quiz to self-check your understanding of the module content. You can also go online
and take this quiz within the module. The online quiz provides the correct answer once
submitted.
1. Which of the following is widely understood among general industry employers as the
“trigger height” above the ground or lower level that requires action to protect
employees from falls?
a. 2 feet
b. 4 feet
c. 6 feet
d. 8 feet
2. Which of the following cause the most fall injuries?
a. Falls down stairs
b. Falls from ladders
c. Falls from roofs
d. Falls from scaffolds
3. What should you do to accomplish effective fall protection?
a. Be familiar with OSHA and company fall-protection rules.
b. Identify and evaluate fall hazards.
c. Check fall protection equipment annually.
d. Assign the job to someone else.
4. Who is responsible for making sure fall protection equipment is used properly?
a. Employers
b. Employees
c. Owners
d. Building managers
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5. Who is responsible to follow safe work practices, use equipment properly, and
participate in training?
a. Employers
b. Owners
c. Employees
d. Building managers
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Module 2: Fall Protection Program Elements
The Fall Protection Program – A System within a System
Believe it or not, all companies have safety management systems. And, as with every system, it
has structure, behavior and results. In fact, you cannot NOT have a safety management system
in your company. The most efficient and effective safety management systems are very
organized with comprehensive written details describing specific safety policies, plans,
programs, processes, procedures and practices. At the other end of the spectrum, the safety
management system is unorganized, inefficient, ineffective, lacking direction, and very
informal. It may appear that the safety management system doesn’t exist in your company, yet
it always does in some form.
To help us understand this principle, take a look at the image of
Sissie the cow. You’re probably thinking, “What does a cow
have to do with safety management systems?” Well, just read
on.
Sissie the cow is actually a very complicated system that has
structure, behavior, and results. You know Sissie is a cow
because she has structure: she looks like a cow. If you watch Sissie for a while, you’ll notice that
she behaves like a cow: usually just eating grass all day. And finally, if you follow Sissie around,
you’ll see that her behavior has results: basically she eliminates waste and produces milk. Okay,
how does Sissie the cow relate to safety management systems? Let’s take a look.
1. Structure. It always exists, but what does it look like? It might be a little hard to describe
the structure of a safety management system, but, just like Sissie the cow, it always has
a structure that ranges from extremely organized and formal to extremely unorganized
and informal.
2. Behavior. The resulting behavior of a formal safety management system differs greatly
from the behavior we see in a safety management system that is informal. If you watch
collective behaviors of managers and employees working within a formal safety
management system, you’ll notice it’s quite different from
resulting behaviors from an unorganized, informal system.
Fall Protection Program Elements
The Fall Protection Program is just one part of the company’s
much larger Safety Management System. And, as with all systems,
it also has structure, behavior, and results.
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There should be at least seven major elements in a successful Fall Protection Program. These
seven major elements include:
1. Commitment: All employees—including company executive officers, managers, and
supervisors—are committed to making the Fall Protection Program succeed. An
employer’s attitude toward job safety and health is reflected by his or her employees. If
the employer commits serious time and money into the Fall Protection Program,
employees will see that and be equally serious about safety.
2. Accountability: Everyone in the company, from top management to each employee,
should be held accountable for following fall protection policies, plans, processes,
procedures and safe work practices. To be held accountable, performance is measured
and consequences result. Employee safety performance is evaluated and one of three
consequences result:
It is rewarded. Safe performance is recognized and rewarded in some way.
It is punished. When justified, unsafe performance should result in some form of
reprimand or disciplinary action.
It is ignored. Yes, ignoring performance is, itself, a consequence.
3. Involvement: All employees, including managers and supervisors, should participate in
making the Fall Protection Program succeed. Employee involvement helps ensure
employees gain some ownership in fall protection procedures and practices, so they’re
more likely to use them when not being supervised.
4. Hazard prevention, identification, and control: Employees anticipate potential fall
hazards as they work throughout the day. Their awareness is such that actual fall
hazards are identified and reported. Employees are involved in controlling fall hazards
by eliminating or substituting the hazards, changing processes and procedures, and
using fall protection systems.
5. Accident investigation: Managers and supervisors promptly investigate all fall accidents
and near misses, and then determine how to eliminate their causes. They conduct a
thorough “analysis” for the express purpose of improving the safety management
system, not assigning blame. Remember, fix the system, not the blame!
6. Education and Training: All employees are educated about the fall hazards in the
workplace and they receive training in how to safely accomplish tasks while working at
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Copyright © 2015 Geigle Safety Group, Inc. Page 12 of 81
elevation, and how to properly use fall protection equipment. The employer must
provide training to each employee who is required to use fall protection. Each employee
should be trained to know at least the following about fall protection:
why it is necessary
when it is necessary
how to properly don, doff, adjust and wear fall protection
the limitations of fall protection
the proper care, maintenance, useful life, and disposal of fall protection
Each employee is required to use fall protection and, before being allowed to perform
work requiring fall protection, each employee must demonstrate:
an understanding of the training
the ability to use fall protection properly
It’s important to know that the element which usually results in more OSHA citations is
the failure to provide adequate fall protection training. If someone is seriously injured or
dies as a result of a fall, OSHA compliance officers (and lawyers in lawsuits) will look long
and hard at your training program because they know that it is the area that is more
likely lacking in due diligence.
7. Analysis and Evaluation: Improving the Fall Protection Program using an effective
analysis and evaluation process is one of the most important safety staff activities.
Managers and supervisors, with help from other employees, should analyze and
evaluate the program's strengths and weaknesses at least once a year. To do this, the
employer should use these basic steps:
Identify what you have.
Compare what exists with what is known to work best.
Make improvements as needed.
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You can learn more about the elements of an effective safety management system in Course
700.
Prepare a Safety and Health Policy
Does your company have a written safety and health policy? It
should. A written policy reflects commitment to a safe,
healthful workplace, summarizes management and employee
responsibilities, and emphasizes the safety and health
program's role in achieving that goal. It allows managers and
supervisors to make decisions about working at elevation
without having to check with the employer. Keep the policy
brief, commit to it, and enforce it. Take a look at a sample policy.
Designate Competent Persons and Qualified Persons
You'll find activities throughout OSHA's workplace safety and
health rules that are required to be conducted by competent
and qualified persons.
Competent person and qualified person are terms that federal
OSHA created to designate individuals who have the training
and expertise to evaluate hazardous conditions, inspect
equipment, evaluate mechanical systems, or train others how to work safely.
Who Can Be Competent and Qualified Persons?
The following definitions for competent and qualified persons are related to fall protection:
Competent Person: A competent person is one who is capable of identifying existing
and predictable fall hazards that are dangerous to employees, and authorized to stop
work and take prompt corrective action to eliminate them.
Qualified Person: A qualified person is one who, by possession of a recognized degree,
certificate, or professional standing or who, by extensive knowledge, training, and
experience, has successfully demonstrated the knowledge, skills, and ability to solve or
resolve problems relating to fall protection at work.
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Determining Who Can Be a Competent or Qualified Person
Although federal OSHA defines competent and qualified persons, it
doesn't provide specifics for determining who can assume these roles.
The following guidelines may help:
Know the OSHA rules that apply to your workplace. The rules
will tell you if you need to designate a competent or a qualified
person.
If an OSHA rule that applies to your workplace requires a competent or a qualified
person, note duties and responsibilities the rule requires the person to perform.
If an OSHA rule that applies to your workplace requires a competent person, that person
must have the authority to take prompt corrective measures to eliminate hazards.
Determine the knowledge, training, and experience the competent or qualified person
needs to meet the rule's requirements.
Designate a person who has the knowledge, training, and experience that meets the
rule's requirements.
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Copyright © 2015 Geigle Safety Group, Inc. Page 15 of 81
Real-World Falls
Two journeyman electricians were relocating power poles to
service job trailers at a landfill. They were using an older digger
derrick truck that had a boom and an auger for drilling holes.
The end of the boom had a motorized hoist for setting the
poles and there were two side-by-side buckets on a separate
onboard aerial work platform at the end of the boom.
At the start of the day, they drilled two holes for poles near a tall shop building and set the
first of two 50-foot poles without incident.
They picked up the second pole using the hoist cable at the end of the digger derrick boom. A
synthetic-fiber lifting strap was wrapped around the pole and attached to the hook. Another
rope was attached to the eye of the strap so that the strap could be loosened from the
ground. After they set the pole, one of the electricians was unable to remove the strap by
tugging on it, so he decided to remove it from the aerial platform.
He climbed the onboard fixed ladder, grabbed the top of the bucket with both hands, and
placed one foot on its outside lower lip. As he swung his other foot over the top of the
bucket, it swiveled vertically and he fell, hitting parts of the truck and landing on the ground.
His injuries included two fractured vertebrae and soft tissue.
Findings
The equipment was not regularly inspected and maintained in safe operating
condition.
The bucket leveling cable, which kept the bucket level as the boom was raised and
lowered, broke under the electrician’s weight, which caused the bucket to swivel.
One of the electricians said that, from time to time, he had checked things on the
truck, such as tires, lights, and oil and water levels, but had not performed a pre-
operation inspection or thorough periodic inspection on the digger derrick or the
aerial boom lift.
The company field superintendent said the truck had not been thoroughly inspected
in over two years.
Source: Oregon OSHA 2014
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Module 2 Quiz
Use this quiz to self-check your understanding of the module content. You can also go online
and take this quiz within the module. The online quiz provides the correct answer once
submitted.
1. Which program element usually results in more OSHA citations due to inadequate
implementation?
a. Commitment
b. Training
c. Accident investigation
d. Hazard identification
2. Safety policies are important because they allow managers and supervisors to
__________.
a. reflect management commitment
b. tell employees what to do in greater detail
c. emphasizes their control over employee behaviors
d. make decisions without having to check with the employer
3. A competent person is one who is can __________ hazards and is authorized to
_________ them.
a. correct, report
b. mitigate, monitor
c. identify, correct
d. view, mitigate
4. A __________ person is one who has successfully demonstrated his or her ability to
solve or resolve problems relating to the subject matter, the work, or the project.
a. qualified
b. authorized
c. competent
d. designated
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5. If OSHA regulations require a competent person, that person must have __________.
a. the authority to take prompt corrective measures to eliminate hazards
b. the responsibility to report any infraction directly to OSHA
c. no other duties other than that of a competent person
d. a formal degree from an accredited college or university
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Module 3: Identifying and Evaluating Fall Hazards
Fall Hazard Defined
A fall hazard is anything in the workplace that could cause an
unintended loss of balance or bodily support and result in a
fall. Fall hazards cause accidents such as the following:
A worker walking near the edge of a loading dock falls
to the lower level.
A worker falls while climbing a defective ladder.
A weak ladder collapses under the weight of a heavy worker carrying tools.
A worker carrying a heavy box falls down a stairway.
Despite the examples above, the vast majority of fall hazards are foreseeable. You can identify
them and eliminate or control them before they cause injuries.
How to Evaluate Fall Hazards
The purpose of evaluating fall hazards is to determine how to eliminate or control them before
they cause injuries. Below are important factors to consider in conducting an evaluation.
Involve Others
You may need others to help you evaluate fall hazards. Involve those who may be exposed to
fall hazards and their supervisors; they'll help you identify the hazards and determine how to
eliminate or control them. Involving others also strengthens your safety and health program.
Your workers' compensation insurance carrier and OSHA will also help you evaluate fall
hazards. Contact your insurance carrier to request a consultation.
Determine How Workers Will Access Elevated Surfaces to Perform Their Tasks
Will workers be using portable ladders, supported scaffolds, aerial lifts, or suspension platforms
to reach their work areas? Which ones will they use? How and where will they use the
equipment?
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Identify Tasks That Could Expose Workers to Falls
For general industry, conduct job hazard analyses (JHAs) for all jobs that might present a fall
hazard. Make sure that all walking/working surfaces are free from clutter and cables and have
the strength to support workers and their equipment.
Identify Hazardous Work Areas
Determine if workers' tasks could expose them to the following fall
hazards:
Holes in walking/working surfaces that they could step into
or fall through
Elevated walking/working surfaces six feet or more above a lower level
Skylights and smoke domes that workers could step into or fall through
Wall openings such as those for windows or doors that workers could fall through
Trenches and other excavations that workers could fall into
Walking/working surfaces from which workers could fall onto dangerous equipment
Hoist areas where guardrails have been removed to receive materials
Sides and edges of walking/working surfaces such as established floors, mezzanines,
balconies, and walkways that are four feet or more above a lower level and not
protected by guardrails at least 39 inches high
Ramps and runways that are not protected by guardrails at least 39 inches high
Leading edges (edges of floors, roofs, and decks) that change location as additional
sections are added
Wells, pits, or shafts not protected with guardrails, fences, barricades, or covers
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Determine How Frequently Workers Will Do Tasks that Expose
Them to Falls
The more frequently a worker is exposed to a fall hazard the more
likely it is that the worker could fall.
Determine If and How Workers Need to Move
Determine whether workers need to move horizontally, vertically, or in both directions to do
their tasks. How workers move to perform tasks can affect their risk of falling. Knowing how
they move to perform tasks can help you determine how to protect them.
Determine the Degree of Exposure
Generally, the more workers that are exposed to a fall hazard, the more likely it is one could
fall.
Determine Hazardous Walking/Walking Surfaces
Identify walking/working surfaces that could expose workers to fall hazards. Examples: floors,
roofs, ramps, bridges, runways, formwork, beams, columns, trusses, and rebar.
Determine Fall Distances
Determine fall distances from walking/working surfaces to lower levels. Generally, workers
must be protected from fall hazards on walking/working surfaces where they could fall four
feet or more to a lower level.
Here are some examples of fall hazards from which employees must be protected by the “four
foot rule”:
Holes and skylights in walking/working surfaces
Wall openings that have an inside bottom edge less than 39 inches above a
walking/working surface
Established floors, mezzanines, balconies, and walkways with unprotected sides and
edges
At any height, workers must also be protected from falling onto or into dangerous equipment.
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Identify Fall Hazards That You Can Eliminate
Eliminating a fall hazard is the most effective fall-protection strategy. Ways to eliminate fall
hazards:
Use tool extensions to perform work from the ground.
Identify fall hazards that you can't eliminate. If you can't eliminate fall hazards, you need
to prevent falls or control them so that workers who may fall are not injured.
Ways to prevent falls include covers, guardrails, handrails, perimeter safety cables, and
personal fall-restraint systems.
Ways to control falls include personal fall-arrest systems, positioning-device systems,
and safety-net systems. Use these fall-protection systems only when you can't eliminate
fall hazards or prevent falls from occurring.
Consider Administrative Controls
Administrative controls help prevent falls by influencing the way people work. Examples include
substituting a safe work practice for a risky one, training workers how to do their jobs safely,
and disciplining those who don't follow safe practices.
Determine Whether Anchorages Are Necessary
If workers use personal fall-arrest or restraint systems, they'll need secure anchorages for their
lifelines or lanyards. Anchorages for personal fall-arrest systems must be able to support at
least 5,000 pounds per attached worker or be designed with a safety factor of at least two—
twice the impact force of a worker free-falling 6 feet. Anchorages for personal fall-restraint
systems must be able to support at least 3,000 pounds per attached worker or be designed with
a safety factor of at least two—twice the peak anticipated dynamic load.
Consider Other Factors That Could Increase the Risk of Falls
Will tasks expose workers to overhead power lines? Will they need to use scaffolds, ladders, or
aerial lifts on unstable or uneven ground? Will they be working during hot, cold, or windy
weather? Consider ergonomics. Will workers need to frequently lift, bend, or move in ways that
put them off balance? Will they be working extended shifts that could contribute to fatigue?
Other factors that could increase the risk of falls include:
Holes in walking/working surfaces that they could step into or fall through
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Elevated walking/working surfaces six feet or more above a lower level
Skylights and smoke domes that workers could step into or fall through
Wall openings such as those for windows or doors that workers could fall through
Trenches and other excavations that workers could fall into
Walking/working surfaces from which workers could fall onto dangerous equipment
Hoist areas where guardrails have been removed to receive materials
Sides and edges of walking/working surfaces such as established floors, mezzanines,
balconies, and walkways that are four feet or more above a lower level and not
protected by guardrails at least 39 inches high
Ramps and runways that are not protected by guardrails at least 39 inches high
Leading edges (edges of floors, roofs, and decks) that change location as additional
sections are added
Wells, pits, or shafts not protected with guardrails, fences, barricades, or covers
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Module 3 Quiz
Use this quiz to self-check your understanding of the module content. You can also go online
and take this quiz within the module. The online quiz provides the correct answer once
submitted.
1. The purpose of evaluating fall hazards is to determine how to eliminate or control
them ________.
a. as the result of a thorough accident investigation
b. anytime they might cause an injury
c. before they cause injuries
d. before OSHA can inspect after an accident
2. Which of the following might be able to help you identify fall hazards in your
workplace?
a. Those exposed to hazards
b. Insurance carrier
c. OSHA consultants
d. Any of the above
3. Workers in general industry must be protected from fall hazards on walking/working
surfaces where they could fall ________ feet or more to a lower level.
a. 2
b. 4
c. 6
d. 10
4. Which of the following is NOT one of the three primary factors that determine the
probability of a fall accident?
a. Distance to exposure
b. Frequency of exposure
c. Duration of exposure
d. Scope of exposure
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5. Ramps and runways should be protected by guardrails at least ________ high.
a. 24 inches
b. three feet
c. 39 inches
d. 4 feet
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Module 4: Supported and Suspended Access
What is Supported Access?
Portable ladders, supported scaffolds, and aerial lifts let you get to a work area and support you
while you work. They make getting to a work area easy, but they can cause falls when they're
not used properly.
Portable Ladders
Portable ladders are versatile, economical, and easy to use. However, workers sometimes use
them without thinking about using them safely. Each year, most workers are injured when they
fall from ladders. Most of the falls are less than 10 feet.
Types of portable ladders: We use ladders to do all sorts of tasks, so it's not surprising that
many types of ladders are available. Let's look at the most common types.
Common types of portable ladders
Straight Ladder (left) The most common type of portable ladder. Length cannot exceed 30 feet. Available in wood, metal, and reinforced fiberglass. Supports only one worker.
Standard Folding Ladder (right) Folding ladders have flat steps, a hinged back, and is not adjustable. For use only on firm, level surfaces. Available in metal, wood, or reinforced fiberglass. Must have a metal spreader or locking arm and cannot exceed 20 feet. Supports only one worker.
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Extension Ladder (left) Extension ladders offer the most length in a general-purpose ladder. They have two or more adjustable sections. The sliding upper section must be on top of the lower section. Made of wood, metal, or fiberglass. Maximum length depends on material. Supports only one worker.
Platform Ladder (right) Platform ladders have a large, stable platform near the top that supports one worker. Length cannot exceed 20 feet.
Trestle Ladder (left) Trestle ladders have two sections that are hinged at the top and form equal angles with the base. Used in pairs to support planks or staging. Rungs are not used as steps. Length cannot exceed 20 feet.
Tripod (Orchard) Ladder (right) Tripod ladders have a flared base and a single back leg that provides support on soft, uneven ground. Length cannot exceed 16 feet. Metal and reinforced fiberglass versions are available. Supports only one worker.
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How Falls from Ladders Occur
Most workers fall from unstable ladders that shift or tilt when the
workers climb too high or reach too far beyond the side rails.
Workers also fall when they slip on rungs while they're climbing or
descending and when vehicles strike the ladders. Workers can
reduce their risk of falling by doing the following:
Inspect ladders frequently and maintain them.
Match work tasks to appropriate ladders.
Set up ladders correctly. Use the 1 to 4 rules. One foot out
from wall for every four feet of height.
Climb and descend ladders properly. Both hands should be
free.
Always use the three-point rule. "Two feet - One hand" or
"Two hands - One foot" making contact at all times.
Required Ladder Safety Training
Before workers use ladders, a competent person must train them so that they understand the
following:
The nature of the fall hazards in the work area.
How to use, place, and care for ladders.
Maximum intended load-carrying capacities of the ladders.
OSHA’s 29 CFR 1910.23-28 requirements for the ladders they use.
Safe Ladder Practices
Keep the following in mind when you use a portable ladder:
Select the most appropriate ladder for the task.
Inspect the ladder before using it; make sure it's in good condition.
Stand at the base of the ladder with your toes touching the rails. Extend your arms straight out in front of you. If the tips of your finger just touch the rung nearest your shoulder level, the angle of your ladder has a 4:1 ratio.
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Angle straight ladders and extension ladders properly. It should have a 4-to-1 slope
(height to base).
Protect the base of a ladder to prevent others from accidentally striking it.
Select a ladder that will extend at least 36 inches above the access area, or provide a
grab rail so that workers can steady themselves as they get on or off. Make sure that the
ladder is stable. If the ladder could be displaced by work activities, secure it.
Face the ladder when you climb or descend it, keeping at least one hand on the rails.
Stay within the side rails when climbing or working from the ladder. You can reach out,
but keep the rest of your body within the rails.
Raise and lower heavy loads with a hand line or a hoist.
Make sure metal ladders have steps and rungs with skid-resistant surfaces.
Allow only one person on the ladder. Use a scaffold if two or more people need to work
together.
Never stand on top of a portable ladder.
Never use ladders that have conductive side rails near exposed energized equipment.
Supported Scaffolds
A supported scaffold is simply an elevated platform that has a rigid means of support. You can
lay a board across a couple of tall buckets, and you have a supported scaffold - but not a safe
one. Most supported scaffolds used for construction work are complex structures and workers
need to know how to erect them, dismantle them, and work from them safely.
Of the many types of supported scaffolds, fabricated frame scaffolds are the most common.
Like portable ladders, they're versatile, economical, and easy to use. You'll see them on
construction sites as single supported platforms and multiple platforms stacked several stories
high on modular frames.
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How Falls from Scaffolds Occur
Workers fall from scaffolds when components fail, planks break, handrails give way, and
scaffold supports collapse. However, most scaffold accidents can be traced to untrained or
improperly trained workers.
Fall-protection systems are required if you work on a supported scaffold more than 10 feet
above a lower level. Guardrails at least 42 plus or minus 3 inches high are appropriate for most
scaffold platforms. If you can't use a guardrail system, then you must use a personal fall-arrest
system or restraint system. We'll discuss personal fall-arrest systems later in the course.
Training for Those Who Work from Scaffolds
Those who work from scaffolds must be trained to recognize fall hazards and to control or
minimize the hazards. Training must cover the following:
Scaffold load capacity and the types of loads appropriate for the scaffold.
When fall protection is required, the appropriate protection to use, and how to use it.
How to use scaffold components.
How to reach access areas.
How to protect those below the scaffold from falling objects.
How to avoid electrical hazards.
Safe Practices While Working on Scaffolds
Use ladders or stairs to reach platforms that are more than 2 feet above or below the
access point.
Don't climb cross-braces to reach a scaffold platform.
Scaffolds must be able to support their own weight and at least four times the
maximum intended load. The maximum intended load includes workers, equipment,
and supplies.
Platforms must not deflect more than 1/60 of the span when they are loaded.
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Platforms must be fully decked or planked between the front uprights and the guardrail
supports.
Don't use damaged scaffold components; repair or replace them immediately.
Make sure a competent person inspects the components before each workshift.
Don't modify components.
Scaffold components made by different manufacturers may be mixed, provided they fit
together without force and maintain structural integrity.
Watch for slippery surfaces. Don't work on platforms covered with snow and ice.
Stay off scaffolds during storms and strong winds unless a competent person
determines that it's safe.
Keep a safe distance from power lines and any other conductive source. Minimum
clearance distances:
o Uninsulated electrical lines: 10 feet
o Insulated lines more than 300 volts: 10 feet
o Insulated lines less than 300 volts: 3 feet
Scaffolds must be erected, dismantled, or moved only under the supervision of a
competent person. The competent person must be on site to direct and supervise the
work.
Aerial Lifts
Aerial lifts are designed to position workers and handle materials when a work surface isn't
easy to reach. The American National Standards Institute (ANSI) classifies aerial lifts as "vehicle-
mounted elevating and rotating work platforms" (ANSI A92.2-1969).
Types of Aerial Lifts
Most aerial lifts have extensible or articulating mechanisms that can position workers up, down,
or sideways. ANSI defines and sets operating standards for four different types of aerial lifts:
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Vehicle-mounted elevating and rotating lifts (ANSI A92.2 devices).
Manually propelled elevating work platforms (ANSI A92.3 devices).
Boom-supported elevating work platforms (ANSI A92.5 devices).
Self-propelled elevating work platforms and scissor lifts (ANSI A92.6 devices).
How Aerial Lift Falls Occur
Most accidents involving aerial lifts can be traced to untrained or improperly trained workers.
Reasons for falls:
A hydraulic cylinder fails and causes the boom to drop.
Outriggers are not used or improperly placed and the lift vehicle overturns.
Workers are not tied off while they are in the bucket.
Workers fall or are pulled off the platform when the lift vehicle is struck by another
vehicle or moves unexpectedly.
Appropriate Fall Protection
If you work from an aerial lift, you must be protected from falling. The type of fall protection
you need depends on the type of lift you use. Most platforms must have a guardrail and each
worker may be required to use a personal fall-arrest system: a full-body harness and lanyard
attached to the boom or the platform.
Safe Practices While Working on Aerial Lifts
Keep in mind the following when you use an aerial lift:
Use the lift only for its intended purpose and follow the manufacturer's instructions.
Keep the operating manual with the lift.
Keep the lift level and stable; use outriggers and intermediate stabilizers.
Never move the lift when the boom is up and workers are on the platform.
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Stand on the platform floor. Don't sit or climb on the edge of the basket, guardrail, or
midrail.
Be sure to close the access gate while you're working from the platform.
Inspect the lift before using it to make sure that it's working properly and is in good
condition.
Know the lift's rated load capacity and don't exceed it.
Stay at least 10 feet away from electrical power lines.
Never use the lift during severe weather.
Use warning signs or barricades to keep others out of the work area.
Never tie off to equipment or to a structure next to the platform.
Portable ladders, supported scaffolds, and aerial lifts provide easy access to most elevated work
areas. When they're not feasible or safe, however, the alternative is a suspended platform.
What is Suspended Access?
Suspended access is a means of getting to
difficult-to-reach work areas on a suspended
platform. Usually the platform is an
adjustable-suspension scaffold. The scaffold,
typically suspended by wire rope from a
rooftop anchor, has a hoist that workers use
to reach the work area.
In some cases, however, even adjustable-
suspension scaffolds may not be feasible or
safe. When there is no other safe way to
reach work area, a crane or a derrick can
provide suspended access by hoisting a personnel platform to reach the work area.
Adjustable-Suspension Scaffolds
A suspension scaffold is a temporary elevated platform that hangs by wire rope. Add a hoist to
move the platform up or down, and you have an adjustable-suspension scaffold—but not
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necessarily a safe one. Suspension ropes, lifelines, platforms, hoists, overhead support devices,
and tieback systems are critical to the safety of adjustable-suspension scaffolds.
How Suspended Scaffold Falls Occur
Most accidents involving adjustable-suspension scaffolds happen when a primary suspension
rope breaks. Workers die because they don't use personal fall-arrest systems or they use them
incorrectly. Steel suspension ropes rarely break if they're correctly rigged, maintained, and
inspected regularly. When the ropes aren't maintained, they weaken. If an ascending platform
snags, an electric hoist that continues to operate can easily snap a weak rope. Pressure from
the two steel discs that clamp to the support rope in sheave-type hoist motors can also break a
weak rope.
Failing anchors also cause serious accidents. Too often, untrained workers attach lifelines and
suspension ropes to "secure-looking" rooftop fixtures for convenience. These anchors fail
because they aren't designed to support suspended loads.
Lifelines fail because workers hang them over unpadded edges, don't inspect them, or use
ropes not designed for personal fall-arrest systems.
Using Adjustable-Suspension Scaffolds
Before you use an adjustable-suspension scaffold, you need to know the engineering principles
for anchoring and suspending the scaffold, how to rig the scaffold, how to operate the hoist,
how to work safely from the scaffold, and what to do in an emergency.
In addition, a competent person must examine all direct connections that are part of the
system and confirm that the connections will support the platform loads. You must also wear a
personal fall-arrest system to protect yourself if a connection fails. Most fatal falls from
suspended platforms result when a support rope fails and workers aren't wearing personal fall-
arrest gear.
When Fall-Protection Systems Are Required
If you work on an adjustable-suspension scaffold more than 10 feet above a lower level, you
must be protected from falling.
Single-point and two-point adjustable-suspension scaffolds: Personal fall-arrest systems
and guardrail systems are required on single-point or two-point adjustable-suspension
scaffolds. The top edge of guardrail must be between 36 inches and 45 inches above the
platform surface. (The top edge can exceed 45 inches when necessary.)
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Boatswain's chairs: Personal fall-arrest systems are required for workers who use
boatswain's chairs.
Multipoint adjustable-suspension scaffolds: Personal fall-arrest systems and guardrail
systems are required on multipoint adjustable-suspension scaffolds. The top edge of the
guardrail must be between 36 inches and 45 inches above the platform surface. (The
top edge can exceed 45 inches, when necessary.)
What You Should Know About Descent-Control Devices
A descent-control device lets you descend a primary support rope—typically from a boatswain's
chair—then lock the device when you reach the work area. The device works by friction,
engaging the support rope and controlling the descent speed. Most workers start from the roof
and work down the face of the building. When they reach the ground, they remove the descent
equipment from the support rope and return to the roof for another drop.
How Falls Occur
Most falls result from failure of the primary support rope or a supporting anchor, not the
descent device. Support ropes fail because workers don't inspect them regularly or they misuse
them. Anchors fail when workers simply assume they are secure. Descent devices, support
ropes, and anchors rarely fail when workers know how to use
them.
Crane- and Derrick-Suspended Personnel Platforms
In some cases, workers may not be able to reach the work area
with stairways, ladders, scaffolds, or aerial lifts. When there is no
other safe way to reach the area, it may be necessary to use a
crane or a derrick and a personnel platform to lift workers to the
area. Employee safety - not practicality or convenience - must be
the basis for your decision to use this method.
How Injuries Occur
Workers rarely fall from suspended personnel platforms. Rather,
most accidents happen when the boom or another part of the
crane contacts an energized power line. Other causes of serious accidents:
Instability: Unstable ground or support surface causes the crane to tip over.
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Lack of communication: The crane operator can't see the suspended platform while it is
moving.
Rigging failure: Platform loads are not properly rigged.
Boom failure: The weight of the loaded platform exceeds the boom's load limit.
Safe Practices
Safe practices for riding personnel platforms to the work area:
Stay within the platform while it's moving.
Wear a body belt or harness and use a lanyard; attach the lanyard to the lower load
block or overhaul ball or to a structural member of the platform.
Stay in view of the crane operator or signal person while you're on the platform.
Before leaving the platform for the work area, secure it to the structure.
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Module 4 Quiz
Use this quiz to self-check your understanding of the module content. You can also go online
and take this quiz within the module. The online quiz provides the correct answer once
submitted.
1. Each year, most workers are injured when they fall from ladders from a height that is
__________.
a. more than 15 feet
b. less than two feet
c. less than 10 feet
d. more than 10 feet
2. What causes most workers to fall from ladders?
a. Ladders that buckle under too much weight
b. Unstable ladders that shift or tilt
c. Ladders that are too small for the task
d. Ladders are cracked or split
3. Most scaffold accidents can be traced to ________.
a. improperly constructed scaffolds
b. improper use of fall protection
c. lack of common sense
d. untrained or improperly trained workers
4. When using an aerial lift, stay at least ________ away from electrical power lines.
a. 4 feet
b. 5 feet
c. 10 feet
d. 12 feet
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5. What causes most falls from suspended scaffolds?
a. Failure of adjustable connectors
b. Failure of control-descent device
c. Failure of emergency descent device
d. Failure of primary support rope or supporting anchor
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Module 5: Fall Protection Systems
What is a Fall Protection System?
If workers will be exposed to fall hazards that you can't eliminate, you'll need to prevent falls
from occurring or ensure that if workers do fall, they aren't injured. A fall protection system is
designed to prevent or arrest falls.
Types of Fall Protection Systems
There are seven general fall-protection systems:
Personal fall-arrest system (PFAS): Arrests a fall
Personal fall-restraint system: Prevents a fall
Positioning-device system: Positions a worker and limits a fall to 2 feet
Guardrail system: Prevents a fall
Safety-net system: Arrests a fall
Warning-line system for roofing work: Warns a worker of a fall hazard
Other Fall-Protection Methods
The following methods may also be appropriate for preventing falls:
Safety monitoring for roofing work: A method in which a person—rather than a
mechanical system—warns roofers when they are in danger of falling. The monitor, who
must be a competent person, is responsible for recognizing the hazards and warning
workers about them.
Catch platforms: Though not covered in OSHA standards, catch platforms are an
acceptable method of protecting workers from falls.
Covers for holes: Simple and effective when they're properly installed, rigid covers
prevent workers from falling through temporary holes, openings, and skylights in
walking/working surfaces.
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Fences and barricades: Use a fence or similar barricade to keep people away from wells,
pits, and shafts.
Identify and Evaluate Fall Hazards
Wherever possible, you need to try to eliminate fall hazards. In many situations, you won't be
able to eliminate fall hazards. Make sure you identify hazards that you can't eliminate and
evaluate each one. The evaluation will help you determine appropriate fall-protection systems
for your work site. Consider the following:
What is the fall distance from the walking/working surface to the next lower level?
How many workers are exposed to the hazard?
What tasks and work areas are associated with the hazard?
How will the workers move—horizontally, vertically, or in both directions—to do their
tasks?
Are secure anchorages available or can they be easily installed near the hazard?
Are there other hazards near the work area, such as overhead power lines?
How will workers be promptly rescued if they are suspended in a personal fall-arrest
system?
Personal Fall-Arrest Systems (PFAS)
A personal fall-arrest system consists of an anchorage, full body harness (FBH), and connection
systems, that work together to stop a fall and to minimize the arrest force. Other parts of the
system may include a lanyard, a deceleration device, and a lifeline.
The personal fall-arrest system is effective only if you know how all of the components work
together to stop a fall. Before you use a personal fall-arrest system, you should know the
following:
How to select and install a secure anchorage.
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How to select and use connectors.
How to put on and use a full-body harness.
How to correctly attach and use a lanyard.
When a deceleration device is necessary.
How to erect and use a lifeline.
The correct procedures for using retractable
devices.
How to estimate fall distances.
How to avoid swing falls.
How to inspect and maintain the system.
How you will be promptly rescued if you fall.
The Anchorage
An anchorage is a secure point of attachment for lifelines, lanyards, or deceleration devices.
How can you be sure that an anchorage is secure? An anchorage for a personal fall-arrest
system must support at least 5,000 pounds. Anchorages that can't support 5,000 pounds must
be designed and installed under the supervision of a qualified person and must be able to
maintain a safety factor of at least two - twice the impact force of a worker free-falling 6 feet. If
you don't know how much weight an anchorage will support, have a qualified person check it
before you trust your life to it.
Anchorage strength is critical, but is not the only factor to consider. Also important:
Anchorage connector: Unless an existing anchorage has been designed to accept a
lanyard or lifeline, you'll need to attach an anchorage connector - a device that provides
a secure attachment point. Examples include tie-off adapters, hook anchors, beam
connectors, and beam trolleys. Be sure that the connector is compatible with the
lanyard or lifeline and appropriate for the work task.
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Attachment point: The anchorage can be used only as the attachment point for a
personal fall-arrest system; it can't be used to support or suspend platforms.
Location: The anchorage should be located directly above the worker, if possible, to
reduce the chance of a swing fall.
Fall distance: Because a personal fall-arrest system doesn't prevent a fall, the anchorage
must be high enough above a worker to ensure that the arrest system, and not the next
lower level, stops the fall. Consider free-fall distance, lanyard length, shock-absorber
elongation, and body-harness stretch in determining the height of an anchorage. Free-
fall distance is the distance a worker falls before a personal fall-arrest system begins to
stop the fall.
Connectors: An anchorage, a lanyard, and a body harness are not useful until they're
linked together. Connectors do the linking; they make the anchorage, the lanyard, and
the harness a complete system. Connectors include carabiners, snap hooks, and D-rings.
Carabiner: This high-tensile alloy steel connector has a locking gate and is used mostly in
specialized work such as window cleaning and high-angle rescue. Carabiners must have
a minimum tensile strength of 5,000 pounds.
Snap hook: A hook-shaped member with a keeper that opens to receive a connecting
component and automatically closes when released. Snap hooks are typically spliced or
sewn into lanyards and self-retracting lifelines. Snap hooks must be high-tensile alloy
steel and have a minimum tensile strength of 5,000 pounds. Use only locking snap hooks
with personal fall-arrest systems; locking snap hooks have self-locking keepers that
won't open until they're unlocked.
D-ring: D-rings are the attachment points sewn into a full-body harness. D-rings must
have a minimum tensile strength of 5,000 pounds.
The Full-Body Harness
A Full-Body Harness (FBH) is used in general industry, construction and any other industry
where work at height is required. Its use protects workers against falls from heights and allows
for travel restraint, positioning, suspension and/or rescue.
The full-body harness has straps that distribute the impact of a fall over the thighs, waist, chest,
shoulders, and pelvis. Full-body harnesses come in different styles, many of which are light and
comfortable.
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Body Belts
Although body belts are not permitted when performing construction work, OSHA does not
address the use of body belts for workers in general industry. However, our opinion is that
workers should never use a body belt as part of a personal fall-arrest system. Body belts should
not be used when fall potential exists: They should be used for positioning only.
Purchasing an FBH for a Personal Fall-Arrest System
Before you purchase harnesses, make sure they fit those who will use them, they're
comfortable, and they're easy to adjust. A full-body harness should include a back D-ring for
attaching lifelines or lanyards and a back pad for support.
Keep the following in mind:
The harness must be made from synthetic fibers.
The harness must fit the user. It should be comfortable and easy to adjust.
The harness must have an attachment point, usually a D-ring, in the center of the back
at about shoulder level. The D-ring should be large enough to easily accept a lanyard
snap hook.
Chest straps should be easy to adjust and strong enough to withstand a fall without
breaking.
Use only industrial full-body harnesses (not recreational climbing harnesses).
The harness must be safe and reliable. It should meet ANSI Z359.11 and CSA Z259.12-11
standards and the manufacturer should have ISO 9001 certification, which shows the
manufacturer meets international standards for product design, development,
production, installation, and service.
Connection Systems - Lanyards
A lanyard is a specially designed flexible line that has a snap hook at each end. One snap hook
connects to the body harness and the other connects to an anchorage or a lifeline. Lanyards
must have a minimum breaking strength of 5,000 pounds. They come in a variety of designs,
including self-retracting types that make moving easier and shock-absorbing types that reduce
fall-arrest forces. Don't combine lanyards to increase length or knot them to make them
shorter.
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Deceleration devices: Deceleration devices protect workers from the impact of a fall and
include shock-absorbing lanyards, self-retracting lifelines or lanyards, and rope grabs.
Shock-absorbing lanyard: A shock absorber reduces the impact on a worker during fall arrest
by extending up to 3.5 feet to absorb the arrest force. OSHA rules limit the arrest force to 1,800
pounds but a shock-absorbing lanyard can reduce the force even more - to about 900 pounds.
Because a shock-absorbing lanyard extends up to 3.5 feet, it's critical that the lanyard stops the
worker before the next lower level. Allow about 20 vertical feet between the worker's
anchorage point and the level below the working surface. Always estimate the total distance of
a possible fall before using a shock-absorbing lanyard. Example: Lanyard length (6 feet) +
deceleration distance (3.5 feet) + worker's height (6 feet) + safety margin (3 feet) = 18.5 vertical
feet from anchorage to lower level.
Never use a shock-absorbing lanyard if the shock absorber is even partially extended or if the lanyard has arrested a fall.
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Self-retracting lanyard/lifeline: Self-retracting lanyards and lifelines offer more freedom to
move than shock-absorbing lanyards. Each has a drum-wound line that unwinds and retracts as
the worker moves. If the worker falls, the drum immediately locks, which reduces free-fall
distance to about 2 feet - if the anchorage point is directly above the worker. Some self-
retracting lanyards will reduce free-fall distance to less than one foot. Self-retracting lanyards
are available in lengths up to 20 feet. Self-retracting lifelines, which offer more freedom, are
available in lengths up to 250 feet.
Self-retracting lanyards and lifelines that limit free-fall distance to 2 feet or less must be
able to hold at least 3,000 pounds with the lanyard (or lifeline) fully extended.
Self-retracting lanyards that don't limit free-fall distance to 2 feet must be able to hold
at least 5,000 pounds with the lanyard (or lifeline) fully extended.
Beware of Swing Falls!
If you use a self-retracting lanyard or lifeline, work below
the anchorage to avoid a swing fall. The farther you move
away from the anchorage, the farther you will fall and the
greater your risk of swinging back into a hard object.
Swing falls are hazardous because you can hit an object or
a lower level during the pendulum motion.
Rope grab: A rope grab allows a worker to move up a
vertical lifeline but automatically engages and locks on the
lifeline if the worker falls. When using a rope grab, keep
the following in mind.
The rope grab must be compatible with the lifeline.
The rope grab must be correctly attached to the
lifeline (not upside down).
Keep the lanyard (between the rope grab and the body harness) as short as possible.
Keep the rope grab as high as possible on the lifeline.
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Lifelines: A lifeline is a cable or rope that connects to a body
harness, lanyard, or deceleration device, and at least one
anchorage. There are two types of lifelines, vertical and
horizontal.
Vertical lifeline: A vertical lifeline is attached to an
overhead anchorage and must be connected directly to a
worker's full-body harness, lanyard, retractable device, or
rope grab; it must have a minimum breaking strength of
5,000 pounds.
When a worker needs to move horizontally, however, a
vertical lifeline can be hazardous due to the potential for a
swing fall - the pendulum motion that results when the
worker swings back under the anchor point. A swing fall
increases a worker's risk of striking an object or a lower
level during the pendulum motion.
Horizontal lifeline: Unlike a vertical lifeline, the horizontal
lifeline stretches between two anchorages. When you
connect a lanyard or rope grab to the horizontal lifeline, you
can move about freely, thus reducing the risk of a swing fall. However, horizontal lifelines are
subject to much greater loads than vertical lifelines due to what is called "sag angle".
Sag angle: The sag angle is the angle of
horizontal lifeline sag when a fall occurs. If
the lifeline is tight, it won't sag much when a
fall occurs, but the impact force on the
lifeline will be higher. Impact force, as used
in this context, is the force or "shock"
imparted to a lifeline by the attached
lanyard. If the lifeline is not so tight, it will
sag more and the impact force on the lifeline
will actually be less. If horizontal lifelines are
not installed correctly, they can fail at the
anchorage points due to these impact forces.
For this reason, horizontal lifelines must be
designed, installed, and used under the supervision of a qualified person.
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Example: If the sag angle is 15 degrees, the impact force, or force amplification, imparted to the
lifeline is only about 2:1. However, when the sag angle is decreased to only 5 degrees, it's
tighter, and the impact force imparted to the lifeline increases to about 6:1. Remember, lifeline
anchorages must be strengthened as impact forces increase. To reduce loads on a horizontal
lifeline, increase the sag angle or connect to the lifeline with a shock-absorbing lanyard.
Safe Practices for Personal Fall-Arrest Systems
Don't tie knots in rope lanyards and lifelines; knots can reduce strength by 50 percent.
Don't tie lifelines or lanyards directly to I-beams; the cutting action of beam edges can
reduce the rope's strength by 70 percent.
Know how the sag angle of a horizontal lifeline can affect arrest forces on the
anchorages. Remember that horizontal lifelines must be designed, installed, and used
under the supervision of a qualified person.
Think about the potential for a swing fall whenever you connect a lifeline to a personal
fall-arrest system.
Remember that a shock-absorbing lanyard will elongate before arresting a fall. The fall
distance includes lanyard length (before the shock absorber extends), deceleration
distance (shock-absorber extension), worker height, and a safety margin (allow 3 feet).
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Real-World Falls
Fall from a Telecommunications Tower
A worker was climbing down a 400-foot
telecommunications tower when he lost his
footing. The ladder safety device or system
(consisting of the carabiner, carrier rail, safety
sleeve and body harness) he used failed to
arrest his fall. The safety sleeve did not
activate correctly to stop the worker’s fall, the
chest D-ring ripped out of the body harness,
and he plunged 90 feet to his death.
Likely Causes of Incident
The worker did not receive proper training on the ladder safety device he used.
The pawl of the sleeve was defective. The defect prevented the device from activating
properly to stop a fall within 2 feet (.61 meters) of its occurrence (29 CFR
1926.1053(a)(22)(iii)). This was identified in a safety notice issued after the incident
and as a result of OSHA’s investigation.
The weight of the worker, his tools and equipment was more than the 310–pound
rating of the body harness.
The safety sleeve was connected to the harness at the chest D-ring instead of to the
navel D-ring as specified by the manufacturer of the ladder safety device.
The body harness was not a component of the manufacturer’s ladder safety device.
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Module 5 Quiz
Use this quiz to self-check your understanding of the module content. You can also go online
and take this quiz within the module. The online quiz provides the correct answer once
submitted.
1. A fall-arrest system ________ the fall and the fall-restraint system _______ the fall.
a. allows, prevents
b. prevents, limits
c. limits, prevents
d. holds, limits
2. Which of the following is not one of the major components of a personal fall-arrest
system?
a. Anchorage
b. Net
c. Full-body harness
d. Connector
3. Anchorages that can't support 5,000 pounds must be designed and installed under the
supervision of __________.
a. the site project manager
b. an OSHA consultant
c. the safety manager
d. a qualified person
4. The harness must have an attachment point, usually a D-ring ________.
a. in the center of the front at chest level
b. on the side at mid-back level
c. in the center of the back at about shoulder level
d. that is adjustable and removable
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5. Which of the following is true regarding lanyards?
a. They have a snap hook at each end.
b. Do not combine lanyards.
c. Minimum breaking strength is 5000 pounds.
d. Each of the above is true.
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Module 6: Fall Protection Systems (Continued)
Personal Fall-Restraint Systems
Unlike the personal fall-arrest system, which is designed to stop
a fall, a personal fall-restraint system prevents a worker from
reaching an unprotected edge and thus prevents a fall from
occurring. The system consists of an anchorage, connectors, and
a body harness or a body belt. The attachment point to the body
belt or full body harness can be at the back, front, or side D-
rings.
The anchorage for a fall-restraint system must support at least
3,000 pounds or be designed and installed with a safety factor of
at least two. If you're not sure how much an anchorage will
support, have a qualified person evaluate it.
Positioning-Device Systems
Positioning-device systems make it easier to work with both hands
free on a vertical surface such as a wall or concrete form.
Positioning-device systems are also called Class II work-positioning
systems and work-positioning systems.
The components of a positioning-device system—anchorage,
connectors, and body support—are similar to those of a personal
fall-arrest system. However, the systems serve different purposes.
A positioning-device system provides support and must stop a free
fall within 2 feet; a personal-fall-arrest system provides no support
and must limit free-fall distance to 6 feet.
Anchorage: Positioning-device systems must be secured to
an anchorage that can support at least twice the potential
impact of a worker's fall or 3,000 pounds, whichever is
greater.
Connectors: Connectors must have a minimum strength of 5,000 pounds. Snap hooks
and D-rings must be proof-tested to a minimum load of 3,600 pounds without
deforming or breaking.
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Body support: A body belt is acceptable as part of a positioning-device system. However,
it must limit the arresting force on a worker to 900 pounds and it can only be used for
body support. A full-body harness is also acceptable and must limit the arrest force to
1,800 pounds. Belts or harnesses must have side D-rings or a single front D-ring for
positioning.
Guardrail Systems
A guardrail system consists of a top rail, midrail, and intermediate vertical member. Guardrail
systems can also be combined with toeboards that prevent materials from rolling off the
walking/working surface.
Guardrail systems must be free of anything that might cut a worker or snag a worker's clothing.
Top rails and midrails must be at least ¼-inch thick to reduce the risk of hand lacerations; steel
or plastic banding cannot be used for top rails or midrails. Other requirements for guardrails:
Wire rope used for a top rail must be marked at least every 6 feet with high-visibility
material.
The top rail of a guardrail must be 42 plus or minus 3 inches above the walking/working
surface. The top-edge height can exceed 45 inches if the system meets all other
performance criteria.
Midrails must be installed midway between the top rail and the walking/working surface
unless there is an existing wall or parapet at least 21 inches high.
Screens and mesh are required when material could fall between the top rail and
midrail or between the midrail and the walking/working surface.
Intermediate vertical members, when used instead of midrails between posts, must be
no more than 19 inches apart.
A guardrail system must be capable of withstanding a 200-pound force applied within 2
inches of its top edge in any outward or downward direction.
Midrails, screens, and intermediate structural members must withstand at least 150
pounds applied in any downward or outward direction.
Safety-Net Systems
Safety-net systems consist of mesh nets and connecting components.
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Safety-net openings can't be more than 6 inches on a side, center to center.
Safety nets must not be installed more than 30 feet below the working surface.
An installed net must be able to withstand a drop test consisting of a 400-pound
sandbag, 30 inches in diameter, dropped from the working surface.
Inspect safety nets regularly and remove debris from them no
later than the start of the next work shift.
The minimum horizontal distance to the net's outer edge depends on how far below the
working surface the net is placed.
Net's distance below work surface Minimum horizontal distance from the edge of
the working surface to the net's outer edge
Up to 5 feet 8 feet
5 to 10 feet 10 feet
More than 10 feet 13 feet
Warning-Line Systems for Roofing Work
Roofing work refers to hoisting, storing, applying, and removing roofing materials and
equipment; it includes work on related insulation, sheet metal, and vapor barriers, but does not
include the construction of the roof deck or leading-edge work. A warning-line system for
roofing work consists of ropes, wires or chains, and supporting stanchions that mark off an area
within which roofing work can be done without guardrails, personal fall-arrest systems,
restraint systems, or safety nets. Warning-line systems can only be used for roofing work on
roofs that have slopes of 2:12 or less, vertical to horizontal. The purpose of the line is to warn
roofers that they are near an unprotected edge.
The warning line must be at least 6 feet from an unprotected edge and meet the following
criteria:
Be flagged at least every 6 feet with high-visibility material.
Be rigged so that the line is 34 to 39 inches from the walking/working surface.
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Have a minimum tensile strength of 500 pounds. Don't use plastic caution tape for a
warning line.
Be attached to each stanchion so that tension on one section of the line will not cause
an adjacent stanchion to tip over. Stanchions must be able to support a force of at least
16 pounds applied horizontally in the direction of the roof edge without tipping over.
Those who do roofing work between the warning line and an unprotected roof edge must be
protected with personal fall-arrest systems, restraint systems, guardrail systems, safety
monitoring systems, or safety nets.
Slide-Guard Systems
A slide-guard system prevents workers
from sliding down a sloped roof. The
system consists of a slide guard (typically
2-by-6-inch lumber) and at least two roof
brackets and must be installed under the
supervision of a competent person. Roof
brackets are available from roofing-
equipment suppliers. A slide-guard system
can also be made at the work site without
manufactured roof brackets. Slide-guard
systems cannot be the only means of fall
protection on roofs with a ground-to-eave
height greater than 25 feet.
Slide guards are not permitted to be used in lieu of conventional fall protection methods during
roofing work (removal, repair, or installation of weatherproofing roofing materials, such as
shingles, tile, and tar paper). However, slide guards must be used as part of a written, site-
specific fall protection plan that meets the requirements of 29 CFR 1926.502(k) if the employer
can demonstrate that the use of conventional fall protection would be infeasible or create
greater hazards.
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Requirements for slide-guard systems:
Slide-guard systems can be used
only on roofs with slopes between
3:12 and 8:12 and ground-to-eave
height of 25 feet or less.
Roofs with slopes between 3:12
and 6:12 must have at least one
slide guard below the work area,
no closer than 6 inches from the
eave.
Roofs with slopes between 6:12
and 8:12 must have multiple slide
guards no more than 8 feet apart
vertically. The lowest slide guard
must be no closer than 6 inches
from the eave.
The slide guard closest to the eave must be perpendicular to the roof surface. All other
slide guards must be set at an angle not less than 60 degrees to the roof surface.
Slide guards must provide continuous protection along the length of the roof.
Manufactured roof brackets
Install manufactured roof brackets according to the manufacturer's directions. Keep the
information at the job site for those who want to review it.
Each bracket must be 6 inches or larger and all brackets must bear on a solid surface.
The horizontal space between brackets cannot exceed the manufacturer's specifications
- or 8 feet - whichever is less.
Attaching slide guards
Use 2-by-6-inch lumber for slide guards. Secure the slide guards to the roof brackets or use
another method to prevent them from cantilevering and failing due to material flex.
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Job-made slide-guard systems
Use 2-by-6-inch lumber for a job-made slide-guard
system. Vertical members must be backed to horizontal
flat members.
Anchor horizontal members to solid bearing surfaces
with two 16-penny common nails or the equivalent
every 4 feet. Anchor vertical members to horizontal
members with one 16-penny common nail or the
equivalent every 2 feet. Vertical members must have
full-support bracing every 8 feet, horizontally.
Safety Monitoring for Roofing Work
When other fall protection methods are not feasible
and a competent person has developed a written plan, safety monitoring systems may be used.
This is a method in which a person, rather than a mechanical system, warns workers doing
repairs when they are in danger of falling. The monitor, who must be a competent person, is
responsible for recognizing fall hazards and warning workers about them. Safety monitoring
systems must meet the requirements of OSHA 29 CFR 1926.502(h).
Safety monitoring can be used only to protect those who do roofing work on roofs that have
slopes less than or equal to 4 in 12 (vertical to horizontal) and widths no greater than 50 feet.
Safety monitoring on roofs wider than 50 feet is not permitted unless a warning-line system
also protects the workers.
The safety monitor's responsibilities:
Recognize fall hazards.
Warn employees when they are
unaware of hazards or aren't working
safely.
Stay on the same walking/working
surface as the workers to see them
and to communicate with them while
they are working.
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Avoid any other work or distracting activity while monitoring the workers.
Only those who are doing roofing work are permitted in the area controlled by the safety
monitor. Mechanical equipment can't be used or stored in the area.
Catch Platforms
Catch platforms, which consist of a stable platform and an attached standard guardrail, can
protect roofers when other systems or methods are not feasible. Platform guidelines:
The platform should not be more than 18 inches below the eave line of the roof.
The platform should extend horizontally at least 2 feet beyond the eave line of the roof.
The platform must have a standard guardrail and toeboard. The top guardrail should rise
substantially (at least 12 inches) above the eave line of the roof. Install intermediate
rails or a solid barrier between the top rail and the platform to prevent a worker from
sliding under the top rail.
Covers for Holes
Simple and effective when they're properly installed, rigid covers prevent workers from falling
through skylights or temporary openings and holes in walking/working surfaces.
Safety criteria for covers:
Will support at least twice (2 times) the maximum expected weight of workers,
equipment, and materials. Skylights are
not considered covers unless they meet
this strength requirement.
Are secured to prevent accidental
displacement.
Have full edge bearing on all four sides.
Are painted with a distinctive color or
marked with the word HOLE or COVER.
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Fences and Barricades
Fences and barricades are warning barriers, usually made from posts and wire or boards, that
keep people away from hazards such as wells, pits, and shafts.
Protecting Workers from Falling Objects
You need to protect yourself from falling when you work on an elevated surface and be aware
of those working above or below you. Protect yourself and others from falling objects with one
of the following methods:
Canopies: Make sure canopies won't collapse or tear from an object's impact.
Toeboards: Toeboards must be least 3½ inches high and strong enough to withstand a
force of at least 50 pounds applied downward or outward.
Panels and screens: If you need to pile material higher than the top edge of a toeboard,
install panels or screens to keep the material from dropping over the edge.
Barricades and fences: Use them to keep people away from areas where falling objects
could hit them.
When doing overhand bricklaying, keep materials and equipment (except masonry and mortar)
at least 4 feet from the working edge. When doing roofing work, keep materials and equipment
at least 6 feet from the roof edge unless there are guardrails along the edge. All piled, grouped,
or stacked material near the roof edge must be stable and self-supporting. No amount of
precaution will work if employees do not use safe work practices.
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Module 6 Quiz
Use this quiz to self-check your understanding of the module content. You can also go online
and take this quiz within the module. The online quiz provides the correct answer once
submitted.
1. In a fall-restraint system, the attachment point to the body belt or full body harness
can be at the back, front, or side D-rings.
a. True
b. False
2. The top rail of a guardrail must be _____ plus or minus ____ inches above the
walking/working surface.
a. 39, 3
b. 42, 3
c. 47, 5
d. 49, 5
3. Safety nets must not be installed more than ______ below the working surface.
a. 6 feet
b. 10 feet
c. 20 feet
d. 30 feet
4. The warning line must be at least ______ from an unprotected edge.
a. 6 feet
b. 10 feet
c. 20 feet
d. 30 feet
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5. Hole covers must support at least ______ the maximum expected weight of workers,
equipment, and materials.
a. 1.5 times
b. 2 times
c. 3 times
d. 4 times
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Module 7: Fall Protection Training
Why Workers Should Be Trained on Fall Protection
Workers need to know about workplace hazards to
which they may be exposed, how to recognize the
hazards, and how to minimize their exposure. The
best way for them to learn is through training.
Training ensures that they know about the hazards
and can demonstrate how to protect themselves
from falling.
Some employers assume that they can train their
employees simply by showing them a fall-protection
training video or online course (like this one!). But
videos, lectures, online courses, etc., are not
adequate because they do not provide the "hands-on" component of the training.
Unfortunately, these training methods only provide instruction.
Employers: Your Responsibility
If you're an employer, you're responsible for ensuring that your employees can recognize fall
hazards and they know how to protect themselves before they're exposed to the hazards. You
can't assume they know how to protect themselves from falls. If they're starting work on a new
site, for example, they might not recognize fall hazards or know how to protect themselves
unless you train them.
Required Training for Employees Exposed to Fall Hazards
Workers who could be exposed to fall hazards must be trained to recognize the hazards and to
know the procedures that minimize the hazards.
The employer should ensure each employee has been trained, as necessary, by a competent
person qualified in the following areas:
The nature of fall hazards in the work area;
The correct procedures for erecting, maintaining, disassembling, and inspecting the fall
protection systems to be used;
OSHAcademy founder, Steve Geigle, on top of a wind turbine up in Canada. Note his fall protection equipment.
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The use and operation of guardrail systems, personal fall arrest systems, safety net
systems, warning line systems, safety monitoring systems, controlled access zones, and
other protection to be used;
The correct procedures for the handling and storage of equipment and materials and
the erection of overhead protection; and
The standards contained in OSHA and company safety regulations.
The Training Format
As an employer, you can determine the training format. What's important is that, through
training, your employees can recognize fall hazards and know procedures to minimize the
hazards.
Who can do the training? It's important that the trainer knows the hazards at the work site,
knows how to eliminate or control the hazards, and knows how to teach workers to protect
themselves. That's why the trainer must be a competent person. (Recall that a competent
person is one who can identify work-site hazards and who has management authority to
control them.) The trainer must know and be able to explain the following:
The nature of fall hazards at the work site.
Procedures for erecting, maintaining, and disassembling fall protection systems.
How to use and operate fall-protection systems.
The role of each employee who may be affected by a safety-monitoring system.
Restrictions that apply to mechanical equipment used during roofing work.
Procedures for handling and storing materials and for erecting protection from falling
objects.
Requirements detailed in OSHA standards.
Company policies and procedures.
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When to Train
Employees must be trained before they begin tasks that could expose them to fall hazards or
before they use fall-protection systems. They must be retrained when you have reason to
believe they don't recognize fall hazards, when they don't follow safe practices for using fall-
protection systems, and when changes in the workplace or in the fall-protection systems used
make their previous training obsolete.
What to Put in Writing
The employer must keep a written record (certification) of each employee's fall-protection
training. As a minimum, you need to include the employee's name, the training date, and the
trainer's signature. Since this training involves procedures and practices that are used to
prevent serious injury or death, I personally recommend you "certify" the employee as qualified
to use the fall protection equipment and that they know procedures. Remember, to certify the
employee as qualified, the employee must prove to the trainer or competent person that they
have adequate knowledge and skills to perform the procedure or practice. A formal certification
record should be developed to document any training that requires employees to know and use
procedures and practices for dangerous tasks. See sample certification record.
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Model Training Strategy
The "show and tell" model for on-the-job training (OJT) has been, and is still, the best method
for training specific fall-protection safety procedures. Measurement knowledge and skills
occurs throughout the OJT process while keeping the employee safe from injury while learning.
If, in using this training method, the employee is not exposed to hazards that could cause
serious injury, you may be able to delete step 3. Otherwise do not skip a step.
Step 1: Introduction - The instructor tells the trainee about the training. At this time, the
instructor emphasizes the importance of the procedure to the success of the
production/service goals, invites questions, and emphasizes accountability.
Step 2: Instructor show and tell - The instructor demonstrates the process. The instructor first
explains and demonstrates safe work procedures associated with the task. In this step the
trainee becomes familiar with each work practice and why it is important.
Trainer: Demonstrates and Explains
Trainee: Observes and Questions
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Step 3: Instructor show and ask- The trainee tells the instructor how to do the procedure, while
the instructor does it. This step is actually optional. It's important to include this step if injury is
possible. There is an opportunity for the instructor to discover whether there were any
misunderstandings, but protects the trainee because the instructor still performs the
procedure.
Trainer: Demonstrates and Questions
Trainee: Explains and Observes
Step 4: Trainee tell and show - Now it's the trainee's turn. To further protect the employee, the
Instructor must give permission for the trainee to perform each step. The trainee carries out
the procedure but remains protected because the he or she explains the process before
actually performing the procedure.
Trainer: Gives permission, Observes and Questions
Trainee: Gets permission, Explains and then Demonstrates
Step 5: Conclusion - The instructor recognizes accomplishment, reemphasizes the importance of
the procedure, and how it fits into the overall process. The instructor also reviews the natural
consequences (the injury/illness) and system consequences (reward/discipline) related to
performance.
Step 6: Document - The trainee certifies (1) training accomplished, (2) questions were
answered, (3) opportunities provided to do procedure, (4) accountabilities understood, and (5)
intent to comply. The instructor certifies that the trainee has (6) demonstrated adequate
knowledge and skill to complete the procedure.
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Real-World Falls
Pipefitter falls from ladder
A pipefitter was going to get a measurement at the top of a 25-foot fiberglass tank. With the
help of a co-worker, he placed a ladder against the tank and tied off the bottom to pipes at
the base of the tank. He climbed the ladder, stood on the top rungs, and took the
measurement.
While he was descending, the ladder slipped against the slick fiberglass surface and twisted.
The pipefitter lost his balance and fell 18 feet to the concrete floor. He died of massive head
injuries.
Findings: The pipefitter had been on the job only four days and had no training in using
ladders safely. Also, the ladder was defective and had not been tagged or removed from
service; the side rails were twisted and dented, the rungs damaged, and the halyard was
missing.
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Module 7 Quiz
Use this quiz to self-check your understanding of the module content. You can also go online
and take this quiz within the module. The online quiz provides the correct answer once
submitted.
1. Why does OSHA consider relying solely on videos, online courses, and classroom
lectures inadequate for fall protection training?
a. Lacks the required 10-hour training requirement
b. Limits the size of the class
c. Does not contain the hands-on component
d. Takes too much time
2. According to OSHA, which of the following is false regarding fall protection training?
a. Must be provided to employees exposed to fall hazards
b. Must enable employees to recognize fall hazards
c. Must train employees on hazard mitigation procedures
d. Must correct all fall protection hazards prior to training
3. What is the response if the employer believes an employee who has been trained
doesn't recognize fall hazards?
a. Discipline the employee
b. Reassign the employee
c. Retrain the employee
d. Terminate the employee
4. Documentation of fall protection training must include which of the following at a
minimum?
a. Employee name, training date, trainer signature
b. Trainer name, training topic, employee signature
c. Employee name, training date
d. Training date, trainer signature
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5. According to the text, what is the best method for training specific fall-protection
safety procedures?
a. Group exercise
b. Guided discussion
c. Lecture
d. Show and tell
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Module 8: Inspection and Maintenance
Caring for Equipment
When you use ladders, scaffolds, aerial lifts, and fall-protection systems you expect to get your
job done safely. But do you pay attention to the condition of the equipment? Inspect the
equipment frequently, keep it clean, store it properly, and it won't let you down.
Inspection and Maintenance
To maintain their service life and high performance, it is very important that you inspect the
components of personal fall-arrest, restraint, or positioning-device systems for damage or
excessive wear before and after each use. Frequent inspection by a competent person should
also be accomplished. Replace any component that looks damaged.
Note: If a fall arrest system has prevented a fall, you can't use it again, but don't throw it away.
Use that harness to tell the story in training about how it saved a life. It's worth its weight in
gold!
Harness Inspection
It is very important that you inspect the components of personal fall-arrest, restraint, or
positioning-device systems for damage or excessive wear before and after each use.
1. Belts and Rings: For harness inspections begin at one end, hold the body side of the belt
toward you, grasping the belt with your hands six to eight inches apart. Bend the belt in
an inverted "U." Watch for frayed edges, broken fibers, pulled stitches, cuts or chemical
damage. Check D-rings and D-ring metal wear pads for distortion, cracks, breaks, and
rough or sharp edges. The D-ring bar should be at a 90 degree angle with the long axis of
the belt and should pivot freely.
o Attachments of buckles and D-rings should be given special attention. Note any
unusual wear, frayed or cut fibers, or distortion of the buckles.
o Rivets should be tight and unremovable with fingers. Body side rivet base and
outside rivets should be flat against the material. Bent rivets will fail under stress.
o Inspect frayed or broken strands. Broken webbing strands generally appear as tufts
on the webbing surface. Any broken, cut or burnt stitches will be readily seen.
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2. Tongue Buckle: Buckle tongues should be free of distortion in shape and motion. They
should overlap the buckle frame and move freely back and forth in their socket. Rollers
should turn freely on the frame. Check for distortion or sharp edges.
3. Friction Buckle: Inspect the buckle for distortion. The outer bar or center bars must be
straight. Pay special attention to corners and attachment points of the center bar.
Lanyards
When inspecting lanyards, begin at one end and work to the
opposite end. Slowly rotate the lanyard so that the entire
circumference is checked. Spliced ends require particular attention.
Hardware should be examined under procedures detailed below.
Hardware
Snaps: Inspect closely for hook and eye distortion, cracks, excessive wear, and corrosion or
pitted surfaces. The keeper or latch should seat into the nose without binding and should not
be distorted or obstructed. The keeper spring should exert sufficient force to firmly close the
keeper. Keeper rocks must provide the keeper from opening when the keeper closes.
Thimbles: The thimble (protective plastic sleeve) must be firmly seated in the eye of the splice,
and the splice should have no loose or cut strands. The edges of the thimble should be free of
sharp edges, distortion, or cracks.
Lanyards
Steel Lanyards: While rotating a steel lanyard, watch for cuts, frayed areas, or unusual wear
patterns on the wire. The use of steel lanyards for fall protection without a shock-absorbing
device is not recommended.
Web Lanyard: While bending webbing over a piece of pipe, observe each side of the webbed
lanyard. This will reveal any cuts or breaks. Paint or other substances should not be on the
webbing as it may contaminate the material. Due to the limited elasticity of the web lanyard,
fall protection without the use of a shock absorber is not recommended.
Rope Lanyard: Rotation of the rope lanyard while inspecting from end to end will bring to light
any fuzzy, worn, broken or cut fibers. Weakened areas from extreme loads will appear as a
noticeable change in original diameter. The rope diameter should be uniform throughout,
following a short break-in period. When a rope lanyard is used for fall protection, a shock-
absorbing system should be included.
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Shock-Absorbing Packs
The outer portion of the shock-absorbing pack should be examined for burn holes and tears.
Stitching on areas where the pack is sewn to the D-ring, belt or lanyard should be examined for
loose strands, rips and deterioration.
Visual Indication of Damage to Webbing and Rope Lanyards
Heat
In excessive heat, nylon becomes brittle and has a shriveled brownish appearance. Fibers will
break when flexed and should not be used above 180 degrees Fahrenheit.
Chemical
Change in color usually appears as a brownish smear or smudge. Transverse cracks appear
when belt is bent over tight. This causes a loss of elasticity in the belt.
Ultraviolet Rays
Do not store webbing and rope lanyards in direct sunlight, because ultraviolet rays can reduce
the strength of some material.
Molten Metal or Flame
Webbing and rope strands may be fused together by molten metal or flame. Watch for hard,
shiny spots or a hard and brittle feel. Webbing will not support combustion, nylon will.
Paint and Solvents
Paint will penetrate and dry, restricting movements of fibers. Drying agents and solvents in
some paints will appear as chemical damage.
Self-Retracting Lifelines
Look for cuts, frayed strands, or excessive wear in the line and damage to the housing. If the
unit needs service, check the manufacturer's recommendations. Don't try to repair it yourself.
See more information about PFAS inspection and maintenance from Miller Fall Protection.
Guardrail Systems
Frequently inspect manila, plastic, or synthetic rope used for top rails or midrails to ensure that
the rope meets the minimum strength and rail height requirements. [See 1926.502(b)]
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Safety-Net Systems
Inspect safety nets for damage or deterioration weekly and
after any event that could damage them. Remove defective
components from service.
Ladders
Remember, not just anyone can or should inspect ladders or
fall protection equipment. A competent person must
inspect ladders periodically. He or she must also inspect
them immediately after any event that could damage them.
General: When inspecting ladders, generally look for loose
steps or rungs (considered loose if they can be moved at all
with the hand), loose nails, screws, bolts, or other metal
parts. Look for cracked, spilt, or broken uprights, braces, or
rungs, slivers on uprights, rungs, or steps. Also look for
damaged or worn non-slip bases.
Step Ladders: On step ladders, make sure they are not
wobbly (from side strain) and do not have loose, bent or broken hinge spreaders, or loose
hinges. Make sure the stop on hinge spreaders are not broken. Finally make sure the steps are
not broken, split or worn.
Extension Ladders: On extension ladders, make sure the extension locks are not loose, broken,
or missing. Make sure locks seat properly while extended, and make sure the rope is not worn,
rotted, cut, or defective in any way.
Scaffolds
A competent person must inspect a scaffold and its components after it has been erected,
before each shift, and after any event—including severe weather—that could damage it. The
inspection should include the foundation, platform, guardrails, and access areas.
Suspension scaffolds
A competent person must inspect suspension ropes before each shift and after any event that
could damage them. Inspect and tighten wire rope clips to the manufacturer's
recommendations at the start of each shift. Inspect manila or synthetic rope used for toprails or
midrails frequently to ensure that it meets the minimum strength and rail height requirements.
[See 1926.502(b)].
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Crane- and Derrick-Suspended Personnel Platforms
After the trial lift: Immediately after a trial lift, a competent person must inspect the
rigging, personnel platform, and the base that supports the crane or derrick.
After proof testing: A competent person must inspect the platform and rigging
immediately after they have been proof tested.
Summary: Inspecting, Cleaning, and Storing Fall-Protection Equipment
Always follow manufacturers' instructions and warnings.
Always inspect equipment before using it. Look for damaged or missing parts. Labels,
warnings, and other instructions should be readable.
If equipment looks like it needs repair, remove it from service and have a competent
person examine it.
Have a competent person inspect equipment regularly.
Mark equipment with a unique code or item number. Identification numbers make it
easier to keep track of the equipment and to document maintenance or repair.
Wash synthetic rope and body harnesses in soapy water to remove dirt; rinse them with
clean water. Air-dry at room temperature. Don't use cleaning solvents; solvents can
damage synthetic material.
Don't lubricate moving parts unless the manufacturer requires it; lubricants attract dirt.
Don't remove information labels and warnings; make sure they're still legible after
cleaning.
Follow manufacturer's instruction for storing equipment.
Store equipment in an area that is clean, dry, and moisture-free; avoid excessive heat,
light, oil, and corrosive chemicals.
More information on cleaning and inspection of fall protection equipment.
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Module 8 Quiz
Use this quiz to self-check your understanding of the module content. You can also go online
and take this quiz within the module. The online quiz provides the correct answer once
submitted.
1. When should you inspect the components of personal fall-arrest, restraint, or
positioning-device systems for damage or excessive wear?
a. Once a week
b. Once a day
c. Before and after each use
d. As needed or directed
2. Do not use a personal fall-arrest system that has arrested a fall unless a competent
person has determined that the system is safe to use.
a. True
b. False
3. Which of the following should be looked for when inspecting harness webbing?
a. Frayed edges
b. Cracks, breaks, rough or sharp edges
c. Loose, bent or broken grommets
d. Stiffness and cracking
4. When inspecting snap-hooks, which of the following defects should be looked for?
a. Cracks, excessive wear, and corrosion
b. Broken fibers and pulled stitches
c. Chemical damage
d. Cuts and burns
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5. According to the text, which of the following need not be looked at while inspecting
scaffolds?
a. Platform
b. Guardrails
c. Foundation
d. Warning zone
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Module 9: Rescue at Height
Prompt Rescue Required
The best strategy for protecting workers from falls is to eliminate the hazards that cause them.
When you can't eliminate the hazards, you must protect workers with an appropriate fall-
protection system or method. If a worker is suspended in a personal fall-arrest system, you
must provide for a prompt rescue.
"Prompt" means without delay. A worker suspended in a harness after a fall can lose
consciousness if the harness puts too much pressure on arteries. A worker suspended in a body
harness must be rescued in time to prevent serious injury. If a fall-related emergency could
happen at your work site, you should have a plan for responding to it promptly. Workers who
use personal fall-arrest systems must know how to promptly rescue themselves after a fall or
they must be promptly rescued.
Developing an Emergency-Response Plan
The following guidelines will help you develop a plan for responding promptly to falls and other
emergencies.
Effective plans don't need to be elaborate. Your plan should show you've thought about
how to eliminate and control hazards and workers know how to respond promptly if
something goes wrong.
Get others involved in planning. When other workers participate, they'll contribute
valuable information, take the plan seriously, and be more likely to respond effectively
during an emergency. Key objectives for an effective emergency-response plan include:
o Identify the emergencies that could affect your site.
o Establish a chain of command.
o Establish procedures for responding to the emergencies.
o Identify critical resources and rescue equipment.
o Train on-site responders.
Identify emergencies that could affect your workplace. Identify any event that could
threaten worker safety or health. Two examples:
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o A worker suspended in a full-body harness after a fall.
o A worker on a scaffold who contacts an overhead power line.
Identify critical resources and rescue equipment. Prompt rescue won't happen without
trained responders, appropriate medical supplies, and the right equipment for the
emergency.
o First-aid supplies: Every work site needs medical supplies for common
injuries. Does your site have a first-aid kit for injuries that are likely to occur?
Store the supplies in clearly marked, protective containers and make them
available to all shifts.
o Rescue equipment: Identify on-site equipment that responders can use to
rescue a suspended worker. Extension ladders and mobile lifts are useful and
available at most sites. Determine where and how each type of equipment
would be most effective during a rescue. Make sure the equipment will
permit rescuers to reach a fall victim, that it's available when rescuers need
it, and that rescuers know how to use it.
Will your longest ladder reach a suspended worker? If not, what equipment will reach the
worker? When equipment is needed for a rescue, will workers know where it is and how to use
it? Think about seasonal and environmental conditions and how they may affect rescue
equipment and those who use it. Equipment that works for summer rescues may not work for
winter rescues.
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Train on-site responders: An effective emergency-response plan ensures that on-site
responders know emergency procedures, know how to use available rescue equipment,
and - if necessary - know how to contact off-site responders. Workers who use personal
fall-arrest systems and who work alone must know how to rescue themselves. Those
who work at a remote site may need a higher level of emergency training than those
who work near a trauma center or a fire department.
Establish a chain of command. All workers must know their roles and responsibilities
during an emergency. A chain of command links one person with overall responsibility
for managing an emergency to those responsible for carrying out specific emergency-
response tasks. Make sure that back-up personnel can take over when primary
responders aren't available.
Establish procedures for responding to emergencies. Procedures are instructions for
accomplishing specific tasks. Emergency procedures are important because they tell
workers exactly what to do to ensure their safety during an emergency. Your
emergency-response plan should include the following procedures—preferably in
writing—that describe what people must know and do to ensure that a fallen worker
receives prompt attention:
o How to report an emergency.
o How to rescue a suspended worker.
o How to provide first aid.
After an emergency, review the procedures; determine if they should be changed to prevent
similar events and revise them accordingly.
Summary: Responding to falls
Before on-site work begins
Identify emergencies that could affect your work site.
Establish a chain of command.
Document procedures for responding to emergencies and make sure they're available at
the site.
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Post emergency-responder phone numbers and addresses at the work site.
Identify critical resources and rescue equipment.
Train on-site responders.
Identify off-site responders and inform them about any conditions at the site that may
hinder a rescue effort.
Identify emergency entry and exit routes.
Make sure responders have quick access to rescue and retrieval equipment, such as lifts
and ladders.
During on-site work
Identify on-site equipment that can be used for rescue and retrieval, such as extension
ladders and mobile lifts.
Maintain a current rescue-equipment inventory at the site. Equipment may change
frequently as the job progresses.
Re-evaluate and update the emergency-response plan when on-site work tasks change.
When an emergency occurs
First responders should clear a path to the victim. Others should direct emergency
personnel to the scene. You can use 911 for ambulance service; however, most 911
responders are not trained to rescue a worker suspended in a personal fall-arrest
system. Make sure only trained responders attempt a technical rescue.
Prohibit all nonessential personnel from the rescue site.
Talk to the victim; determine the victim's condition, if possible.
If you can reach the victim, check for vital signs, administer CPR, attempt to stop
bleeding, and make the victim comfortable.
After an emergency
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Report fatalities and catastrophes to OSHA within eight hours.
Report injuries requiring overnight hospitalization and medical treatment (other than
first aid) to OSHA within 24 hours.
Identify equipment that may have contributed to the emergency and put it out of
service. Have a competent person examine equipment. If the equipment is damaged,
repair or replace it. If the equipment caused the accident, determine how and why.
Document in detail the cause of the emergency.
Review emergency procedures. Determine how the procedures could be changed to
prevent similar events; revise the procedures accordingly.
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Module 9 Quiz
Use this quiz to self-check your understanding of the module content. You can also go online
and take this quiz within the module. The online quiz provides the correct answer once
submitted.
1. If a worker is suspended in a personal fall-arrest system, you must provide for a
prompt rescue. "Prompt" means _________.
a. within 15 minutes
b. as soon as possible
c. without delay
d. when emergency services arrive
2. Which of the following is a key planning objective in an effective emergency-response
plan?
a. A chain of command
b. Response procedures
c. On-site responder training
d. Each of the above
3. According to the text, to ensure a fallen worker receives prompt attention, your
emergency-response plan should include all of the following, EXCEPT:
a. How to provide first aid
b. How to rescue a suspended worker
c. How to report an emergency
d. How to discipline for non-compliance
4. You can use 911 for ambulance service because most 911 responders are trained to
rescue a worker suspended in a personal fall-arrest system.
a. True
b. False
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5. An effective fallen worker emergency-response strategy primarily relies on ________.
a. fire department responders
b. emergency medical services
c. on-site responders
d. air rescue services